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Yamaha FT50C Service Manual

Other manuals for FT50C: Servise Manual, Service Manual

Summary of FT50C

  • Page 1

    Service manual 62y-28197-5a-11 290418 ft50c.

  • Page 2

    Notice this manual has been prepared by yamaha primarily for use by yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical conc...

  • Page 3: Contents

    Contents general information 1 gen info specifications 2 spec periodic checks and adjustments 3 chk adj fuel system 4 fuel power unit 5 powr lower unit 6 lowr bracket unit 7 brkt electrical systems 8 elec troubleshooting 9 trbl shtg index – +.

  • Page 4: General Information

    Gen info 62y5a11 general information how to use this manual ................................................................................. 1-1 manual format............................................................................................ 1-1 symbols........................................

  • Page 5

    62y5a11 1 2 3 4 5 6 7 8 9 predelivery checks ...................................................................................... 1-26 checking the fuel system ........................................................................ 1-26 checking the gear oil..........................................

  • Page 6

    Gen info general information 1-1 62y5a11 how to use this manual 1 manual format the format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. 1 parts are shown and detailed in an exploded...

  • Page 7

    62y5a11 1-2 1 2 3 4 5 6 7 8 9 symbols the symbols below are designed to indicate the content of a chapter. General information specifications periodic checks and adjustments fuel system power unit lower unit bracket unit electrical systems troubleshooting gen info spec chk adj fuel powr lowr brkt el...

  • Page 8

    Gen info general information 1-3 62y5a11 safety while working 1 to prevent an accident or injury and to ensure quality service, follow the safety pro- cedures provided below. Fire prevention gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flame...

  • Page 9

    62y5a11 1-4 1 2 3 4 5 6 7 8 9 6. Keep a supply of clean, lint-free cloths for wiping up spills, etc. Good working practices special tools use the recommended special tools to pro- tect parts from damage. Use the right tool in the right manner—do not improvise. Tightening torques follow the tightenin...

  • Page 10

    Gen info general information 1-5 62y5a11 1 model name 2 approved model code 3 transom height 4 serial number features and benefits 1 use of leaded gasoline new ft50c/f50d is designed for pleasure/light commercial use for all over the world. Therefore, engine components anti-corrosion and reliability...

  • Page 11

    62y5a11 1-6 1 2 3 4 5 6 7 8 9 cdi unit with microcomputer the ignition system consists of a flywheel, stator, pulser coil, thermoswitch, oil pressure switch, cdi unit, and ignition coil. The cdi unit contains a built-in microcomputer that determines the ignition timing separately for acceleration an...

  • Page 12

    Gen info general information 1-7 62y5a11 lower unit higher class pinion and gears the lower unit of the new ft50c uses the same type of large gears that are used in the f100. The use of the same type of gears that are used in a higher class model provides ample durability, mak- ing it possible to ac...

  • Page 13

    62y5a11 1-8 1 2 3 4 5 6 7 8 9 shift slider type shift mechanism the ft50c has adopted the shift slider type shift mechanism. This shift mechanism enables a prompt engagement of the dog clutch regardless of the operating speed of the shift lever. Thus, smooth and positive shift operation has been mad...

  • Page 14

    Gen info general information 1-9 62y5a11 1 prime start 2 intake manifold of the engine 3 thermo heater plunger 4 fuel enrichment valve 5 to carburetor #2 or #4 6 carburetor 7 intake silencer È air É fuel Ê plunger movement 1 prime start È the enriched air-fuel mixture is delivered to cylinders #1 an...

  • Page 15

    62y5a11 1-10 1 2 3 4 5 6 7 8 9 carburetor operation 1. Idle and low-speed operation since the vacuum at the venturi is low when the throttle valve is opened slightly, the main nozzle does not supply any air-fuel mixture to the engine. When the engine is operating at idle, the fuel that passes throug...

  • Page 16

    Gen info general information 1-11 62y5a11 2. Medium speed operation when the throttle valve opens further, air-fuel mixture is fed from the pilot outlet and all the bypass holes. In addition, air-fuel mixture is also supplied from the main nozzle in accordance with the opening angle of the throttle ...

  • Page 17

    62y5a11 1-12 1 2 3 4 5 6 7 8 9 3. High-speed operation when the throttle valve approaches its fully open position, the fuel that has been regulated by the main jet and the air that has been regulated by the main air jet are mixed in the main nozzle. The resultant mixture is then sprayed by the main ...

  • Page 18

    Gen info general information 1-13 62y5a11 acceleration pump the function of the acceleration pump is to ensure a smooth acceleration by preventing the air-fuel mixture from becoming temporarily lean in case the throttle valve is opened suddenly. When the throttle valve is opened suddenly, a large vo...

  • Page 19

    62y5a11 1-14 1 2 3 4 5 6 7 8 9 operation when the throttle is opened suddenly, diaphragm 1 (via the link that is connected to the throttle lever) operates to pressurize the air in the pump chamber. The pressurized air opens diaphragm 2, and becomes distributed to the carburetors by passing through t...

  • Page 20

    Gen info general information 1-15 62y5a11 ignition system in order to determine the optimal ignition timing that is necessary for the proper operation of the engine, the built-in microcomputer in the cdi unit detects the signals from various types of sensors and controls the ignition timing in accor...

  • Page 21

    62y5a11 1-16 1 2 3 4 5 6 7 8 9 pulser coil the pulser coil transmits the pulser signals, which are generated in the pulser coil in accordance with the rotation of the flywheel, to the cdi unit. Among the two protrusions that are provided for generating signals, one is used for cylinders #1 and #4, a...

  • Page 22

    Gen info general information 1-17 62y5a11 ignition timing control control circuit diagram basic control the ignition timing is determined by using the map based on the engine speed (r/min). Then, igni- tion signals are output from the microcomputer in accordance with the ignition timing map so that ...

  • Page 23

    62y5a11 1-18 1 2 3 4 5 6 7 8 9 starting control when starting the engine, the timing is set to 5° btdc until the crankshaft speed maintains 600 r/min for two seconds or longer. 1 cylinder identification protrusion 2 protrusion for cylinders #1 and #4 3 pulser coil 4 protrusion for cylinders #2 and #...

  • Page 24

    Gen info general information 1-19 62y5a11 acceleration control this control is activated when the throttle valve is opened suddenly. If the engine speed increases more than the specified figures, the control of the ignition timing transfers to the acceleration map. Thereafter, the control of the ign...

  • Page 25

    62y5a11 1-20 1 2 3 4 5 6 7 8 9 hydraulic system diagram 1 power trim and tilt cylinder 2 ram 3 reservoir 4 manual valve 5 down-main valve 6 down-relief valve 7 hydraulic pump 8 up-relief valve 9 up-main valve power trim and tilt components 1 cylinder 2 ram 3 check valve 4 down-main valve 5 down-reli...

  • Page 26

    Gen info general information 1-21 62y5a11 trim-up function the gear pump pumps power trim and tilt fluid to the up-main valve. As a result, the fluid pressure opens the up-shuttle piston causing the fluid to flow into the lower part of the power trim and tilt cyl- inder. At the same time, vacuum fro...

  • Page 27

    62y5a11 1-22 1 2 3 4 5 6 7 8 9 trim-down function when the power trim and tilt switch is pressed to “down”, the motor turns the gear pump counter- clockwise and the power trim and tilt fluid flows in the opposite direction to that of the trim-up func- tion. Tilt-up function when the trim cylinder to...

  • Page 28

    Gen info general information 1-23 62y5a11 circular flow 1 power trim and tilt cylinder 2 ram 3 trim cylinder 4 motor 5 reservoir 6 up-relief valve 7 gear pump 8 free piston 9 tilt piston È return É send : : 1 2 3 4 5 6 5 7 8 9 s62y1410

  • Page 29

    62y5a11 1-24 1 2 3 4 5 6 7 8 9 tilt-down function when the power trim and tilt switch is pressed to “down”, the motor turns the gear pump counter- clockwise, thus pumping the power trim and tilt fluid to the down-main valve. As a result, fluid pres- sure opens the down-main valve and the down-shuttl...

  • Page 30

    Gen info general information 1-25 62y5a11 stopping condition when the power trim and tilt switch is not pushed (released), the gear pump does not pump the fluid, the up-main valve and the down-main valve are closed, and the power trim and tilt fluid pres- sure in the system remains constant. This al...

  • Page 31

    62y5a11 1-26 1 2 3 4 5 6 7 8 9 propeller selection 1 the performance of a boat and outboard motor will be critically affected by the size and type of propeller you choose. Propellers greatly affect boat speed, acceleration, engine life, fuel economy, and even boating and steering capabilities. An in...

  • Page 32

    Gen info general information 1-27 62y5a11 checking the gear oil 1. Check the gear oil level. Caution: do not reuse the gasket, always replace it with a new one. Checking the engine oil 1. Check the oil level. Note: • if the engine oil is above the maximum level mark a, drain sufficient oil until the...

  • Page 33

    62y5a11 1-28 1 2 3 4 5 6 7 8 9 3. Check that the alignment mark c is aligned with the mark d. Adjust if neces- sary. Caution: the shift/throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) e. Checking the steering system 1. Check the steering friction for proper adjustment. 2. Check...

  • Page 34

    Gen info general information 1-29 62y5a11 4. Check that the trim meter points down when the outboard motor is tilted all the way down. Checking the engine start switch and engine stop switch/engine shut-off switch 1. Check that the engine starts when the engine start switch is turned to start. 2. Ch...

  • Page 35: Specifications

    62y5a11 spec 1 2 3 4 5 6 7 8 9 specifications general specifications................................................................................... 2-1 maintenance specifications .......................................................................... 2-3 power unit...............................

  • Page 36

    Spec specifications 2-1 62y5a11 general specifications 2 item unit model ft50cehd ft50ced ft50cet dimension overall length mm (in) 1,384 (54.5) 718 (28.3) overall width mm (in) 361 (14.2) overall height (l) mm (in) 1,436 (56.5) boat transom height (l) mm (in) 508 (20.0) weight (with aluminum propell...

  • Page 37

    62y5a11 2-2 1 2 3 4 5 6 7 8 9 * ron: research octane number fuel and oil fuel type unleaded gasoline/leaded gasoline fuel rating ron* 91 engine oil type 4-stroke motor oil engine oil grade api sae se, sf, sg, sh 10w-30, 10w-40, or 20w-40 engine oil quantity (with oil filter replacement) l (us qt, lm...

  • Page 38

    Spec specifications 2-3 62y5a11 maintenance specifications 2 power unit item unit model ft50cehd ft50ced ft50cet power unit minimum compression pressure* kpa (kgf/cm 2 , psi) 840 (8.4, 122) lubrication oil pressure at 55 °c (131 °f), with 10w-30 engine oil kpa (kgf/cm 2 , psi) @ 900 r/min 100 (1.0, ...

  • Page 39

    62y5a11 2-4 1 2 3 4 5 6 7 8 9 2nd ring dimension b mm (in) 1.47–1.49 (0.058–0.059) dimension t mm (in) 2.49–2.51 (0.098–0.099) end gap mm (in) 0.30–0.50 (0.012–0.020) side clearance mm (in) 0.03–0.07 (0.001–0.003) oil ring dimension b mm (in) 2.34–2.46 (0.092–0.097) dimension t mm (in) 2.75 (0.108) ...

  • Page 40

    Spec specifications 2-5 62y5a11 margin thickness (d) intake mm (in) 0.6–1.0 (0.024–0.039) exhaust mm (in) 0.7–1.1 (0.028–0.043) stem diameter intake mm (in) 5.48–5.49 (0.2157–0.2161) exhaust mm (in) 5.46–5.47 (0.2150–0.2153) guide inside diameter intake and exhaust mm (in) 5.50–5.51 (0.2165–0.2169) ...

  • Page 41

    62y5a11 2-6 1 2 3 4 5 6 7 8 9 lower unit electrical fuel pump discharge l (us gal, imp gal)/hr @ 6,000 r/min 70 (18.5, 15.4) pressure kpa (kgf/cm 2 , psi) 49 (0.49, 7.0) plunger stroke mm (in) 5.85–9.05 (0.23–0.35) carburetor id mark 62y30, 62y50 (for brazil) main jet # #1: 124, #2: 126, #3: 116, #4...

  • Page 42

    Spec specifications 2-7 62y5a11 pulser coil output peak voltage (w/r – w/b) @ cranking 1 (*1) v 6.3 @ cranking 2 (*1) v 3.5 @ 1,500 r/min v 7.4 @ 3,500 r/min v 11.2 pulser coil resistance (*2) (w/r – w/b) Ω 396–594 cdi unit output peak voltage (b/o – b, b/w – b) @ cranking 1 (*1) v 126 @ cranking 2 ...

  • Page 43

    62y5a11 2-8 1 2 3 4 5 6 7 8 9 charging system fuse a 20 lighting coil output peak voltage (g – g) @ cranking (*1) v 11.9 @ 1,500 r/min (*1) v 42 @ 3,500 r/min (*1) v 127 lighting coil resistance (*2) (g – g) Ω 1.2–1.8 rectifier regulator output peak voltage (r – b) @ 1,500 r/min (*1) v 18.9 @ 3,500 ...

  • Page 44

    Spec specifications 2-9 62y5a11 dimensions exterior w2 w5 w1 w3 w6 l3 l7 l2 l10 h9 h5 h7 h10 h8 h4 h3 h11 h1 l8 c1 l5 l9 l4 a3 a2 h6 h2 l6 l1 a1 s62y2230

  • Page 45

    62y5a11 2-10 1 2 3 4 5 6 7 8 9 symbol unit model ft50cehd l1 mm (in) 576 (22.7) l2 mm (in) 272 (10.7) l3 mm (in) 797 (31.4) l4 mm (in) 560 (22.0) l5 (l) mm (in) 97 (3.8) (x) mm (in) — l6 (l) mm (in) 990 (39.0) (x) mm (in) — l7 mm (in) 397 (15.6) l8 mm (in) 189 (7.4) l9 (l) mm (in) 0.8 (0.03) (x) mm ...

  • Page 46

    Spec specifications 2-11 62y5a11 exterior.

  • Page 47

    62y5a11 2-12 1 2 3 4 5 6 7 8 9 symbol unit model ft50ced ft50cet l1 mm (in) 576 (22.7) l2 mm (in) 142 (5.6) l3 mm (in) — l4 mm (in) 560 (22.0) l5 (l) mm (in) 97 (3.8) (x) mm (in) — l6 (l) mm (in) 990 (39.0) (x) mm (in) — l7 mm (in) 397 (15.6) l8 mm (in) 149 (5.9) l9 (l) mm (in) 0.8 (0.03) (x) mm (in...

  • Page 48

    Spec specifications 2-13 62y5a11 clamp bracket symbol unit model ft50cehd ft50ced ft50cet b1 mm (in) 126 (5.0) b2 mm (in) 254 (10.0) b3 mm (in) 163.5 (6.4) b4 mm (in) 50.8 (2.0) b5 mm (in) 180 (7.1) b6 mm (in) 355 (14.0) b7 mm (in) — b8 mm (in) 139 (5.5) b9 mm (in) 18.5 (0.7) c2 mm (in) — c3 mm (in)...

  • Page 49

    62y5a11 2-14 1 2 3 4 5 6 7 8 9 tightening torques 2 specified torques part to be tightened thread size tightening torques n·m kgf·m ft·lb power unit flywheel magnet nut — 160 16 116 stator base screw m6 4 0.4 2.9 cover screw m6 3 0.3 2.2 negative battery lead bolt m8 9 0.9 6.5 positive battery lead ...

  • Page 50

    Spec specifications 2-15 62y5a11 general torques this chart specifies tightening torques for standard fasteners with a standard iso thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this man- ual. To avoid warpage, tighten mult...

  • Page 51

    62y5a11 chk adj 1 2 3 4 5 6 7 8 9 periodic checks and adjustments special service tools ..................................................................................... 3-1 maintenance interval chart............................................................................ 3-2 top cowling ......

  • Page 52

    Chk adj periodic checks and adjustments 3-1 62y5a11 special service tools 3 oil filter wrench 90890-01426 digital tachometer 90890-06760 timing light 90890-03141 leakage tester 90890-06762.

  • Page 53

    62y5a11 3-2 1 2 3 4 5 6 7 8 9 maintenance interval chart 3 use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Note: • if operating in salt water, turbid or muddy water, flush the engine with fr...

  • Page 54

    Chk adj periodic checks and adjustments 3-3 62y5a11 top cowling 3 checking the top cowling 1. Check the fitting by pushing the cowling with both hands. Adjust if necessary. 2. Loosen the nuts and bolts 1. 3. Move the hook 2 up or down slightly to adjust its position. Note: • to loosen the fitting, m...

  • Page 55

    62y5a11 3-4 1 2 3 4 5 6 7 8 9 power unit 3 checking the engine oil 1. Place the outboard motor in an upright position. 2. Remove the engine oil dipstick, wipe it clean, and then insert it back into the oil filler hole. 3. Remove the dipstick again to check the oil level and the oil for discoloration...

  • Page 56

    Chk adj periodic checks and adjustments 3-5 62y5a11 4. Apply a thin coat of the new engine oil to the o-ring of the new oil filter. 5. Install the oil filter, and then tighten it to the specified torque. 6. Install the drain bolt, and then tighten it to the specified torque. 7. Fill the specified en...

  • Page 57

    62y5a11 3-6 1 2 3 4 5 6 7 8 9 2. Remove the spark plugs, fuel pump 2, and cylinder head cover 3. 3. Turn the flywheel clockwise and align the “1” mark a on the driven sprocket with the “ ” mark b on the cylinder head. Caution: do not turn the flywheel counterclock- wise, otherwise the valve system m...

  • Page 58

    Chk adj periodic checks and adjustments 3-7 62y5a11 7. Loosen the locknut 4, and then turn the adjusting screw 5 until the specified valve clearance is obtained. Note: • to decrease the valve clearance, turn the adjusting screw clockwise. • to increase the valve clearance, turn the adjusting screw c...

  • Page 59

    62y5a11 3-8 1 2 3 4 5 6 7 8 9 checking the thermostat 1. Remove the cover 1, thermostat cover 2, and thermostat 3. 2. Suspend the thermostat in a container of water. 3. Place a thermometer in the water and slowly heat the water. 4. Check the thermostat valve opening at the specified water temperatur...

  • Page 60

    Chk adj periodic checks and adjustments 3-9 62y5a11 3. Check for water flow at the cooling water outlet. If there is no water flow, check the cooling water passage inside the out- board motor. Control system 3 checking the throttle cable operation 1. Check that the throttle cam 1 is at the fully clo...

  • Page 61

    62y5a11 3-10 1 2 3 4 5 6 7 8 9 4. Align the set pin a in the center of the shift bracket with the alignment mark b on the bracket. 5. Adjust the position of the shift cable joint until its hole is aligned with the set pin. Caution: the shift cable joint must be screwed in a minimum of 8.0 mm (0.31 i...

  • Page 62

    Chk adj periodic checks and adjustments 3-11 62y5a11 checking the ignition timing 1. Start the engine and warm it up for 5 min- utes. 2. Attach the special service tool to high- tension cord #1 1, and then check the engine idle speed. 3. Attach the special service tool to high- tension cord #1 1. 4....

  • Page 63

    62y5a11 3-12 1 2 3 4 5 6 7 8 9 checking the power trim and tilt fluid level 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. Warning after tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could sud- denly...

  • Page 64

    Chk adj periodic checks and adjustments 3-13 62y5a11 4. Install the check screw, and then tighten it to the specified torque. Replacing the gear oil 1. Tilt the outboard motor up slightly. 2. Place a drain pan under the drain screw 1, remove the drain screw, then the check screw 2 to drain the oil. ...

  • Page 65

    62y5a11 3-14 1 2 3 4 5 6 7 8 9 checking the lower unit (for air leakage) 1. Remove the check screw 1, and then install the special service tool. 2. Apply the specified pressure to check whether the lower unit can hold it for at least 10 seconds. Caution: • do not over pressurize the lower unit, othe...

  • Page 66

    Chk adj periodic checks and adjustments 3-15 62y5a11 È ehd, ed models É et model caution: do not oil, grease, or paint the anodes, otherwise they will be ineffective. 2. Replace the anodes and trim tab if excessively eroded. Checking the battery 1. Check the battery electrolyte level. If the level i...

  • Page 67

    62y5a11 3-16 1 2 3 4 5 6 7 8 9 note: • batteries vary per manufacturer. The pro- cedures mentioned in this manual may not always apply, therefore, consult the instruc- tion manual of the battery. • disconnect the negative lead first, then the positive lead. Lubrication 1. Apply water resistant greas...

  • Page 68

    Chk adj periodic checks and adjustments 3-17 62y5a11 2. Apply anti-corrosion grease to the areas shown..

  • Page 69: Fuel System

    62y5a11 fuel 1 2 3 4 5 6 7 8 9 fuel system special service tools ..................................................................................... 4-1 hose routing ................................................................................................... 4-2 fuel and blowby hoses..........

  • Page 70

    Fuel fuel system 4-1 62y5a11 special service tools 4 vacuum/pressure pump gauge set 90890-06756 digital tachometer 90890-06760 vacuum gauge 90890-03159 vacuum gauge (digital) (commercially obtainable) vacuum gauge (4 analog meters) (commercially obtainable) vacuum gauge adaptor (commercially obtaina...

  • Page 71

    62y5a11 4-2 1 2 3 4 5 6 7 8 9 hose routing 4 fuel and blowby hoses 1 blowby hose 2 hose (acceleration pump-to-carburetor) 3 fuel hose (fuel joint-to-fuel filter) 4 fuel hose (fuel filter-to-fuel pump) 5 fuel hose (fuel pump-to-carburetor) 6 hose (carburetor-to-carburetor) special service tools / hos...

  • Page 72

    Fuel fuel system 4-3 62y5a11 fuel filter and fuel pump 4.

  • Page 73

    62y5a11 4-4 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 fuel joint 1 2 fuel filter 1 3 fuel pump 1 4 bolt 1 m6 × 25 mm 5 seal 1 6 fuel hose 1 fuel joint-to-fuel filter 7 clip 3 8 bolt 1 m8 × 14 mm 9 nut 1 10 bracket 1 11 fuel hose 1 fuel filter-to-fuel pump 205.0 mm (8.1 in) 12 fuel hose 2 fuel p...

  • Page 74

    Fuel fuel system 4-5 62y5a11 checking the fuel pump 1. Install the special service tool onto the fuel pump as shown. 2. Apply the specified pressure to each fuel pump port. 3. If air flow is reversed, check the dia- phragm for tears and the valves for cracks. Replace if necessary. Caution: do not ov...

  • Page 75

    62y5a11 4-6 1 2 3 4 5 6 7 8 9 3. Slowly let up on the plunger and dia- phragm, and then remove them. Checking the diaphragm and valves 1. Check the diaphragm 1 for tears and the valves 2 for cracks. Replace if neces- sary. Assembling the fuel pump 1. Align the plunger and diaphragm installa- tion ho...

  • Page 76

    Fuel fuel system 4-7 62y5a11 carburetor unit 4.

  • Page 77

    62y5a11 4-8 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 carburetor assembly 1 joint-to-silencer 2 clip 1 3 blowby hose 1 4 prime start coupler 1 5 bolt 2 m6 × 30 mm 6 collar 2 7 throttle link rod 1 8 o-ring 8 not reusable 34.5 × 1.9 mm 9 insulator 1 10 dowel pin 2 11 bolt 8 m6 × 25 mm 12 fuel hos...

  • Page 78

    Fuel fuel system 4-9 62y5a11 carburetor 4.

  • Page 79

    62y5a11 4-10 1 2 3 4 5 6 7 8 9 È carburetors #1, #2, and #3 É carburetor #4 Ê carburetors #1 and #3 no. Part name q’ty remarks 1 carburetor body 1 2 screw 4 m4 × 13 mm 3 cover 1 4 seal 1 not reusable 5 pilot jet 1 6 main jet 1 7 needle valve 1 8 main nozzle 1 9 o-ring 1 not reusable 10 plug 1 11 flo...

  • Page 80

    Fuel fuel system 4-11 62y5a11 checking the carburetor 1. Check the air and fuel passages and jets, for dirt and foreign matter. Clean the car- buretor body with a petroleum based sol- vent if necessary. 2. Blow compressed air into all passages and jets. Caution: • direct the compressed air downward,...

  • Page 81

    62y5a11 4-12 1 2 3 4 5 6 7 8 9 note: • the float should be resting on the needle valve 4, but not compressing it. • take measurements at the top of the float flange opposite its pivoted side. Checking the prime start 1. Measure the length of the prime start plunger. 2. Connect the positive prime sta...

  • Page 82

    Fuel fuel system 4-13 62y5a11 3. Install the pilot screw 9, turn it in until it is lightly seated, then out the specified number of turns. Adjusting the throttle link rod 1. Push the throttle control lever 1 to the fully open position as shown, and then measure the gap between the carburetor throttl...

  • Page 83

    62y5a11 4-14 1 2 3 4 5 6 7 8 9 3. Turn the pilot screws 2 in direction a until the engine idle speed has decreased to approximately 50 r/min, then in direction b 5/8 turn. 4. Turn the throttle stop screw 3 in direc- tion c or d until the specified engine idle speed is obtained. Note: • to increase t...

  • Page 84

    Fuel fuel system 4-15 62y5a11 4. Adjust the idle speed to 1,000 r/min by turning the throttle stop screw 4 on car- buretor #4 in direction a or b. Note: • to increase idle speed, turn the throttle stop screw in direction a. • to decrease idle speed, turn the throttle stop screw in direction b. 5. Me...

  • Page 85

    62y5a11 4-16 1 2 3 4 5 6 7 8 9 3. Open the throttle cam 2 slowly, and check the engine speed when the accel- eration pump stopper 3 comes into con- tact with point a. 4. If out of specification, adjust the engine speed at the operation point of dash-pot. 5. Open the throttle cam 2 slowly, and check ...

  • Page 86: Power Unit

    Powr 62y5a11 power unit special service tools ..................................................................................... 5-1 power unit....................................................................................................... 5-3 checking the compression pressure ...............

  • Page 87

    62y5a11 1 2 3 4 5 6 7 8 9 cylinder body ............................................................................................... 5-35 removing and installing the oil filter ........................................................ 5-37 disassembling the cylinder body .............................

  • Page 88

    Powr power unit 5-1 62y5a11 special service tools 5 compression gauge 90890-03160 flywheel holder 90890-06522 flywheel puller 90890-06521 crankshaft holder 18 90890-06562 valve spring compressor 90890-04019 valve spring compressor attachment 90890-06320 valve guide remover/installer 90890-06801 valv...

  • Page 89

    62y5a11 5-2 1 2 3 4 5 6 7 8 9 bearing outer race attachment 90890-06626 oil filter wrench 90890-01426 piston slider 90890-06529 special service tools.

  • Page 90

    Powr power unit 5-3 62y5a11 power unit 5.

  • Page 91

    62y5a11 5-4 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 flywheel magnet 1 2 stator coil 1 3 cover 1 4 grommet 2 5 nut 1 6 washer 1 7 bolt 3 m6 × 25 mm 8 lighting coil coupler 1 9 charge coil coupler 1 10 stator base 1 11 pulser coil coupler 1 12 screw 4 m6 × 24 mm 13 dowel pin 2 14 woodruff key 1...

  • Page 92

    Powr power unit 5-5 62y5a11.

  • Page 93

    62y5a11 5-6 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 throttle cable 1 2 shift cable 1 3 fuel pump 1 4 fuel filter assembly 1 5 carburetor assembly 1 6 bolt 3 m6 × 20 mm 7 plate 1 8 clip 1 9 clip 1 10 grommet 1 11 holder 1 12 bolt 2 13 o-ring 1 not reusable 24.4 × 3.1 mm 14 clip 2 15 fuel hose ...

  • Page 94

    Powr power unit 5-7 62y5a11.

  • Page 95

    62y5a11 5-8 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 power trim and tilt relay 1 et model 2 bolt 1 m8 × 16 mm 3 negative battery lead 1 4 wiring harness extension 1 5 grommet 1 6 nut 1 7 spring washer 1 8 positive battery lead 1 9 ptt relay positive lead 1 et model 10 fuse holder lead 1 11 cli...

  • Page 96

    Powr power unit 5-9 62y5a11.

  • Page 97

    62y5a11 5-10 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 bracket 1 2 starter motor 1 3 spark plug cap 4 4 ignition coil 2 5 wiring harness 1 6 thermoswitch 1 7 holder 1 8 bolt 1 m6 × 12 mm 9 ground lead 3 10 bolt 1 m6 × 12 mm 11 oil pressure switch 1 12 oil pressure switch lead 1 13 screw 1 14 ig...

  • Page 98

    Powr power unit 5-11 62y5a11 no. Part name q’ty remarks 1 power unit 1 2 engine oil dipstick 1 3 gasket 1 not reusable 4 dowel pin 2 5 bolt 2 m6 × 16 mm 6 bolt 8 m8 × 80 mm 7 apron 1 8 screw 2 m6 × 24 mm 9 nut 2.

  • Page 99

    62y5a11 5-12 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 throttle link rod 1 2 throttle cam 1 3 throttle control lever 1 4 clip 1 5 bushing 1 6 bolt 1 m6 × 20 mm 7 spring 1 8 collar 1 9 bracket 1 10 bolt 1 m6 × 30 mm 11 shift rod 1 12 bolt 1 m6 × 30 mm 13 bracket 1 14 spring 1 15 bolt 1 power uni...

  • Page 100

    Powr power unit 5-13 62y5a11 checking the compression pressure 1. Start the engine, warm it up for 5 min- utes, and then turn it off. 2. Remove the clip from the engine shut-off switch on the remote control box or tiller handle. 3. Remove the all spark plugs, and then install the special service too...

  • Page 101

    62y5a11 5-14 1 2 3 4 5 6 7 8 9 caution: • apply force in the direction of the arrows shown, to prevent the flywheel holder from slipping off easily. • to prevent damage to the engine or tools, screw in the flywheel puller set bolts evenly and completely so that the flywheel puller plate is parallel ...

  • Page 102

    Powr power unit 5-15 62y5a11 4. Disconnect the battery leads 5, 10-pin coupler 6, ptt relay leads 7 (et), ptt motor leads 8 (et), ground lead 9 (et), warning indicator coupler 0 (ehd), trailer switch coupler a (et), pilot water hose b. 5. Remove the power trim and tilt relay c, shift rod d and shift...

  • Page 103

    62y5a11 5-16 1 2 3 4 5 6 7 8 9 timing belt and sprockets 5 no. Part name q’ty remarks 1 timing belt 1 2 drive sprocket 1 3 driven sprocket 1 4 bolt 1 5 bolt 1 m8 × 20 mm 6 tensioner 1 7 spring 1 8 nut 1 9 retaining plate 2 10 woodruff key 1 11 bolt 1 m10 × 40 mm 12 washer 1 13 bolt 2 m6 × 20 mm 14 b...

  • Page 104

    Powr power unit 5-17 62y5a11 removing the timing belt and sprockets 1. Set the cylinder #1 piston position to tdc of the compression stroke by align- ing the “1” mark a on the driven sprocket with the “ ” mark b on the cylinder head. Caution: do not turn the drive sprocket counter- clockwise, otherw...

  • Page 105

    62y5a11 5-18 1 2 3 4 5 6 7 8 9 checking the timing belt and sprockets 1. Check the interior and exterior of the tim- ing belt for cracks, damage, or wear. Replace if necessary. 2. Check the drive sprocket 1 and driven sprocket 2 for cracks, damage, or wear. Replace if necessary. Installing the sproc...

  • Page 106

    Powr power unit 5-19 62y5a11 3. Check that the “ ” mark c on the retain- ing plate is aligned with the “ ” mark d on the cylinder body. 4. Install the timing belt 7 from the drive sprocket side with its part number in the upright position. Caution: • do not twist, turn inside out, or bend the timing...

  • Page 107

    62y5a11 5-20 1 2 3 4 5 6 7 8 9 caution: do not turn the sprockets counterclock- wise, otherwise the valve system may be damaged. 9. Tighten the driven sprocket bolt 2 to the specified torque. 10. Tighten the drive sprocket nut 6 to the specified torque, and then install the breather hose. Note: use ...

  • Page 108

    Powr power unit 5-21 62y5a11 cylinder head 5.

  • Page 109

    62y5a11 5-22 1 2 3 4 5 6 7 8 9 È tightening sequence no. Part name q’ty remarks 1 cylinder head 1 2 oil pump 1 3 cylinder head cover 1 4 bolt 7 m6 × 20 mm 5 cylinder head cover gasket 1 not reusable 6 bolt 10 m9 × 95 mm 7 spark plug 4 8 bolt 5 m6 × 25 mm 9 dowel pin 2 10 cylinder head gasket 1 not r...

  • Page 110

    Powr power unit 5-23 62y5a11 no. Part name q’ty remarks 1 rocker arm assembly 8 2 rocker arm shaft 1 3 exhaust valve 4 4 intake valve 4 5 camshaft 1 6 valve cotter 16 7 spring retainer 8 8 valve spring 8 9 spring seat 8 10 stem seal 8 not reusable 11 valve guide 8 not reusable 12 retaining bolt 1 13...

  • Page 111

    62y5a11 5-24 1 2 3 4 5 6 7 8 9 removing the cylinder head 1. Check that the camshaft dowel pin hole a is in the position shown in the illustra- tion. Adjust if necessary. 2. Remove the cylinder head cover bolts in the sequence shown. 3. Remove the cylinder head bolts in the sequence shown. Caution: ...

  • Page 112

    Powr power unit 5-25 62y5a11 5. Remove the retaining bolt 4, then the camshaft 5 by pulling it downward. 6. Remove the intake valve and exhaust valves. Note: • be sure to keep the valves and other parts in the order that they were removed. • when replacing the valve, also replace the valve guide and...

  • Page 113

    62y5a11 5-26 1 2 3 4 5 6 7 8 9 3. Measure the valve stem diameter b. Replace if out of specification. 4. Measure the valve stem runout. Replace if out of specification. Checking the valve guides 1. Measure the valve guide inside diameter a. Replace if out of specification. Replacing the valve guides...

  • Page 114

    Powr power unit 5-27 62y5a11 2. Install the new valve guide 2 by striking the special service tool from the cam- shaft side until the valve guide clip 3 contacts the cylinder head. Note: apply engine oil to the surface of the new valve guide. 3. Insert the special service tool into the valve guide 2...

  • Page 115

    62y5a11 5-28 1 2 3 4 5 6 7 8 9 refacing the valve seat 1. Reface the valve seat with the valve seat cutter. 2. Cut the surface of the valve seat with a 45° cutter by turning the cutter clockwise until the valve seat face has become smooth. A slag or rough surface caution: do not over cut the valve s...

  • Page 116

    Powr power unit 5-29 62y5a11 b previous contact width 5. Use a 45° cutter to adjust the contact width of the valve seat to specification. B previous contact width c specified contact width 6. If the valve seat contact area is too wide and situated in the center of the valve face, use a 30° cutter to...

  • Page 117

    62y5a11 5-30 1 2 3 4 5 6 7 8 9 10. After every lapping procedure, be sure to clean off any remaining lapping com- pound from the cylinder head and the valve. 11. Check the valve seat contact area of the valve again. Checking the rocker arms and rocker arm shaft 1. Check the rocker arms, rocker arm s...

  • Page 118

    Powr power unit 5-31 62y5a11 4. Calculate the camshaft oil clearance e as follows. Replace the camshaft and cylinder head as a set if out of specifica- tion. Checking the cylinder head 1. Eliminate carbon deposits from the com- bustion chambers and check for deterio- ration. 2. Check the cylinder he...

  • Page 119

    62y5a11 5-32 1 2 3 4 5 6 7 8 9 installing the valves 1. Install the new valve stem seal 1 to the valve guide, and then apply engine oil to the valve guide. 2. Install the valve 2, spring seat 3, valve spring 4, and spring retainer 5 in the sequence shown, and then attach the special service tool. No...

  • Page 120

    Powr power unit 5-33 62y5a11 installing the camshaft 1. Install the new oil seal 1. 2. Install the camshaft 2 in the direction shown, then the retaining bolt 3. Installing the rocker arm assembly 1. Check that the camshaft dowel pin hole a is in the position shown in the illustra- tion. Adjust if ne...

  • Page 121

    62y5a11 5-34 1 2 3 4 5 6 7 8 9 3. Install the rocker arm shaft assembly to the cylinder head by installing the bolts, and then tighten them to the specified torque and in the sequence shown. Installing the cylinder head 1. Install the oil pump 1 by aligning the oil pump drive shaft a with the camsha...

  • Page 122

    Powr power unit 5-35 62y5a11 cylinder body 5.

  • Page 123

    62y5a11 5-36 1 2 3 4 5 6 7 8 9 È tightening sequence no. Part name q’ty remarks 1 oil filter 1 2 crankshaft 1 3 bolt 10 m8 × 82 mm 4 bolt 10 m6 × 35 mm 5 crankcase 1 6 oil seal 1 not reusable 7 main bearing 10 8 oil seal 1 not reusable 9 connecting rod bearing 8 10 connecting rod cap 4 11 bolt 8 12 ...

  • Page 124

    Powr power unit 5-37 62y5a11 removing and installing the oil filter 1. Place a rag under the oil filter, and then remove the filter. Note: be sure to clean up any oil spills. 2. Apply a thin coat of the new engine oil to the o-ring of the new oil filter. 3. Install the oil filter, and then tighten i...

  • Page 125

    62y5a11 5-38 1 2 3 4 5 6 7 8 9 caution: do not scratch or damage the mating sur- faces of the cylinder head and cylinder body. 3. Remove the connecting rod bolts and the piston assemblies. 4. Remove the crankshaft, oil seals, and dowel pins. 5. Remove the piston pin clip 1 with pliers, and then remo...

  • Page 126

    Powr power unit 5-39 62y5a11 2. Calculate the taper limit. Replace or rebore the cylinder body if out of specifi- cation. 3. Calculate the out-of-round limit. Replace or rebore the cylinder body if out of spec- ification. Checking the piston clearance 1. Rebore the cylinder or replace the piston and...

  • Page 127

    62y5a11 5-40 1 2 3 4 5 6 7 8 9 checking the piston ring grooves 1. Measure the piston ring grooves. Replace the piston if out of specification. Checking the piston ring side clearance 1. Measure the piston ring side clearance. Replace the piston and piston rings as a set if out of specification. Che...

  • Page 128

    Powr power unit 5-41 62y5a11 checking the connecting rod small end inside diameter 1. Measure the connecting rod small end inside diameter a. Replace the connect- ing rod if out of specification. Checking the connecting rod big end side clearance 1. Measure the connecting rod big end side clearance ...

  • Page 129

    62y5a11 5-42 1 2 3 4 5 6 7 8 9 2. Measure the crankshaft runout. Replace the crankshaft if out of specification. Checking the crankshaft main journal oil clearance 1. Clean the bearings, main journals, and bearing portions of the crankcase and cylinder body. 2. Place the cylinder body upside down on...

  • Page 130

    Powr power unit 5-43 62y5a11 7. Tighten the crankcase bolts to the speci- fied torques in two stages and in the sequence shown. Note: do not move the crankshaft until the main journal oil clearance measurement has been completed. 8. Remove the crankcase and measure the width of the compressed plasti...

  • Page 131

    62y5a11 5-44 1 2 3 4 5 6 7 8 9 note: be sure not to put the plastigauge (pg-1) over the oil hole in the crank pin of the crank- shaft. 4. Install the connecting rod to the crank pin 3. Note: • align the alignment marks b on the con- necting rod cap and connecting rod. • face the embossed “y11” mark ...

  • Page 132

    Powr power unit 5-45 62y5a11 selecting the crankshaft main journal bearing 1. When replacing the main bearing, select the suitable bearing as follows. 2. Check the crankshaft journal mark on the crankshaft 1 and the cylinder body mark on the cylinder body 2. 3. Select the suitable color a for the ma...

  • Page 133

    62y5a11 5-46 1 2 3 4 5 6 7 8 9 3. Select the suitable color a for the con- necting rod bearing from the table. 4. When installing the connecting rod bear- ing, insert the projection of the connect- ing rod bearing into the slot on the connecting rod. Caution: remove any small metal particles and oil...

  • Page 134

    Powr power unit 5-47 62y5a11 note: • face the embossed “y11” mark a on the connecting rod in the same direction as the “up” mark b on the piston. • always use new piston pin clips, and do not allow the piston pin clip end to align with the piston pin slot c. 2. Install the oil ring 5, second ring 6,...

  • Page 135

    62y5a11 5-48 1 2 3 4 5 6 7 8 9 6. Install half of the bearings 9 into the cyl- inder body 0. Note: insert the projection f of the bearing into the notch in the cylinder body. 7. Set the crankshaft a, and oil seals b and c into the cylinder body as shown. Apply engine oil to the inner oil seal, jour-...

  • Page 136

    Powr power unit 5-49 62y5a11 10. Apply gasket maker ® to the mating sur- face of the crankcase. Note: • insert the projection h of the bearing into the notch in the crankcase. • do not get any gasket maker on the journal bearings. 11. Install the crankcase bolts, and then tighten them to the specifi...

  • Page 137

    62y5a11 5-50 1 2 3 4 5 6 7 8 9 4. Install the shift rod bolts 6, shift rod 7 and power trim and tilt relay 8. 5. Connect the pilot water hose 9, trailer switch coupler 0 (et), warning indicator coupler a (ehd), ground lead b (et), ptt motor leads c (et), ptt relay leads d (et), 10-pin coupler e, and...

  • Page 138

    Powr power unit 5-51 62y5a11 8. Install the woodruff key. 9. Install the flywheel magnet and flywheel magnet cover. Caution: apply force in the direction of the arrows shown, to prevent the flywheel holder from slipping off easily. Note: apply engine oil to the flywheel magnet nut before installatio...

  • Page 139: Lower Unit

    62y5a11 lowr 1 2 3 4 5 6 7 8 9 lower unit special service tools ..................................................................................... 6-1 lower unit ....................................................................................................... 6-5 removing the lower unit ......

  • Page 140

    Lowr lower unit 6-1 62y5a11 special service tools 6 stopper guide plate 90890-06501 center bolt 90890-06504 bearing separator 90890-06534 stopper guide stand 90890-06538 bearing puller 90890-06535 bearing puller claw 1 90890-06536 needle bearing attachment 90890-06610, 90890-06611, 90890-06612, 9089...

  • Page 141

    62y5a11 6-2 1 2 3 4 5 6 7 8 9 bearing inner race attachment 90890-06639, 90890-06643, 90890-06661, 90890-06662 drive shaft holder 4 90890-06518 pinion nut holder 90890-06505 bearing outer race puller 90890-06523 outer race puller claw a 90890-06532 driver rod sl 90890-06602 bearing outer race attach...

  • Page 142

    Lowr lower unit 6-3 62y5a11 digital caliper 90890-06704 shimming plate 90890-06701 shift rod push arm 90890-06052 backlash indicator 90890-06706 magnet base plate 90890-07003 dial gauge set 90890-01252 magnet base 90890-06705 ring nut wrench 3 90890-06511 ring nut wrench extension 90890-06513 bearin...

  • Page 143

    62y5a11 6-4 1 2 3 4 5 6 7 8 9 ball bearing attachment 90890-06655 socket adapter 2 90890-06507 special service tools.

  • Page 144

    Lowr lower unit 6-5 62y5a11 lower unit 6 no. Part name q’ty remarks 1 lower unit 1 2 plastic tie 1 not reusable 3 hose 1 4 check screw 1 5 gasket 2 not reusable 6 dowel pin 2 7 bolt 4 m10 × 40 mm 8 drain screw 1 9 grommet 1 10 bolt 1 m10 × 45 mm 11 bolt 1 m8 × 60 mm 12 thrust washer 1 13 propeller 1...

  • Page 145

    62y5a11 6-6 1 2 3 4 5 6 7 8 9 removing the lower unit 1. Drain the gear oil. For draining proce- dures, see chapter 3, “replacing the gear oil.” 2. Set the gearshift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning,...

  • Page 146

    Lowr lower unit 6-7 62y5a11 water pump and shift rod 6.

  • Page 147

    62y5a11 6-8 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 shift rod assembly 1 2 oil seal 1 not reusable 3 oil seal housing 1 4 o-ring 1 not reusable 49.4 × 3.1 mm 5 circlip 1 6 shift rod 1 7 o-ring 1 not reusable 6.8 × 1.9 mm 8 bolt 2 m6 × 16 mm 9 woodruff key 1 10 bolt 2 m8 × 55 mm 11 bolt 2 m8 ×...

  • Page 148

    Lowr lower unit 6-9 62y5a11 removing the water pump and shift rod 1. Remove the water pump assembly and shift rod assembly 1. Note: pull up the shift rod assembly a little a to dis- connect it from the shift slider 2, turn it coun- terclockwise 90° b, and then remove it. Checking the water pump and ...

  • Page 149

    62y5a11 6-10 1 2 3 4 5 6 7 8 9 5. Install the woodruff key a into the drive shaft. 6. Align the groove on the impeller 0 with the woodruff key a, and then install it to the drive shaft. 7. Install the insert plate cartridge b and grommet c into the pump housing d. Note: align the insert plate cartri...

  • Page 150

    Lowr lower unit 6-11 62y5a11 propeller shaft housing 6.

  • Page 151

    62y5a11 6-12 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 propeller shaft assembly 1 2 propeller shaft housing assembly 1 3 ball 2 4 slider 1 5 shift plunger 1 6 cross pin 1 7 dog clutch 1 8 spring 1 9 propeller shaft 1 10 washer 1 11 straight key 1 12 claw washer 1 13 ring nut 1 14 reverse gear 1...

  • Page 152

    Lowr lower unit 6-13 62y5a11 removing the propeller shaft housing assembly 1. Straighten the claw washer tabs a, and then remove the ring nut and claw washer. 2. Pull out the propeller shaft housing assembly. Disassembling the propeller shaft housing 1. Remove the reverse gear and thrust washer. Not...

  • Page 153

    62y5a11 6-14 1 2 3 4 5 6 7 8 9 disassembling the propeller shaft assembly 1. Remove the spring 1, and then remove the cross pin 2, dog clutch 3, slider and shift plunger. Checking the propeller shaft housing 1. Clean the propeller shaft housing using a soft brush and cleaning solvent, and then check...

  • Page 154

    Lowr lower unit 6-15 62y5a11 assembling the propeller shaft assembly 1. Install the dog clutch as shown. Note: install the dog clutch 1 with the “f” mark a facing toward the shift slider. Assembling the propeller shaft housing 1. Install the needle bearing into the propel- ler shaft housing to the s...

  • Page 155

    62y5a11 6-16 1 2 3 4 5 6 7 8 9 4. Install the reverse gear assembly to the propeller shaft housing using a press. Installing the propeller shaft housing 1. Install the washer 1, propeller shaft assembly 2, into the propeller shaft housing assembly 3. 2. Apply grease to the new o-rings. 3. Install th...

  • Page 156

    Lowr lower unit 6-17 62y5a11 drive shaft and lower case 6.

  • Page 157

    62y5a11 6-18 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 drive shaft 1 2 taper roller bearing 1 not reusable 3 bearing outer race 1 not reusable 4 pinion shim — as required 5 sleeve 1 6 hose 1 200.0 mm (7.9 in) 7 plastic tie 1 not reusable 8 joint 1 9 nut 1 10 water inlet cover 2 11 screw 1 12 se...

  • Page 158

    Lowr lower unit 6-19 62y5a11 removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the forward gear. Disassembling the drive shaft 1. Install the pinion nut 1, tighten it finger tight, and then remove the drive shaft bearing 2 using a press. Caution: • do not pres...

  • Page 159

    62y5a11 6-20 1 2 3 4 5 6 7 8 9 disassembling the lower case 1. Remove the taper roller bearing outer race and shim(s). Note: install the claws as shown. 2. Remove the drive shaft bearing outer race, shim(s), and drive shaft sleeve. Note: install the claws as shown. 3. Remove the needle bearing. Chec...

  • Page 160

    Lowr lower unit 6-21 62y5a11 checking the lower case 1. Check the skeg and torpedo for cracks or damage. Replace if necessary. Assembling the lower case 1. Install the needle bearing into the lower case to the specified depth. Note: • install the needle bearing with the manufac- ture identification ...

  • Page 161

    62y5a11 6-22 1 2 3 4 5 6 7 8 9 2. Install the new needle bearing into the forward gear to the specified depth. Assembling the drive shaft 1. Install the new drive shaft bearing into the drive shaft using a press. Note: use the special service tool or a general pipe with the specified measurements. I...

  • Page 162

    Lowr lower unit 6-23 62y5a11 2. Install the two dowel pins 1 to the lower unit. 3. Install the lower unit to the upper case, and then tighten the bolts to the specified torque. 4. Install the trim tab 2 to its original posi- tion, and then connect the speedometer hose 3. 5. Install the propeller and...

  • Page 163

    62y5a11 6-24 1 2 3 4 5 6 7 8 9 shimming 6 drive shaft and lower case / shimming.

  • Page 164

    Lowr lower unit 6-25 62y5a11 shimming note: • shimming is not required when assembling the original lower case and inner parts. • shimming is required when assembling the original inner parts and a new lower case. • shimming is required when replacing the inner part(s). Selecting the pinion shims 1....

  • Page 165

    62y5a11 6-26 1 2 3 4 5 6 7 8 9 example: if “m” is “32.10 mm” and “p” is “+5”, then t3 = 32.10 – 31.50 – (+5)/100 mm = 0.60 – 0.05 mm = 0.55 mm if “m” is “32.10 mm” and “p” is “–5”, then t3 = 32.10 – 31.50 – (–5)/100 mm = 0.60 + 0.05 mm = 0.65 mm 5. Select the pinion shim(s) (t3) as follows. Example:...

  • Page 166

    Lowr lower unit 6-27 62y5a11 example: if “m” is “24.00 mm” and “f” is “+5”, then t1 = 24.50 + (+5)/100 – 24.00 mm = 0.50 + 0.05 mm = 0.55 mm if “m” is “24.00 mm” and “f” is “–5”, then t1 = 24.50 + (–5)/100 – 24.00 mm = 0.50 – 0.05 mm = 0.45 mm 3. Select the forward gear shim(s) (t1) as follows. Exam...

  • Page 167

    62y5a11 6-28 1 2 3 4 5 6 7 8 9 note: install the dial gauge so that the plunger a contacts the mark b on the backlash indica- tor. 5. Slowly turn the drive shaft clockwise and counterclockwise and measure the back- lash when the drive shaft stops in each direction. 6. Add or remove shims if out of s...

  • Page 168: Bracket Unit

    Brkt 62y5a11 bracket unit special service tools ..................................................................................... 7-1 tiller handle .................................................................................................... 7-2 bottom cowling ...............................

  • Page 169

    62y5a11 1 2 3 4 5 6 7 8 9 power trim and tilt motor............................................................................. 7-43 checking the power trim and tilt motor .................................................... 7-44 assembling the power trim and tilt motor ...............................

  • Page 170

    Brkt bracket unit 7-1 62y5a11 special service tools 7 cylinder-end screw wrench 90890-06544 digital circuit tester 90890-03174.

  • Page 171

    62y5a11 7-2 1 2 3 4 5 6 7 8 9 tiller handle 7 no. Part name q’ty remarks 1 bolt 1 m8 × 30 mm 2 nut 1 3 wing nut 1 4 friction piece 1 5 bolt 1 m6 × 35 mm 6 friction rod 1 7 washer 1 8 nut 1 9 washer 2 10 link rod 1 11 nut 1 12 plate 1 13 bolt 3 m6 × 20 mm 14 grommet 1 15 cable guide 1 16 grommet 1 17...

  • Page 172

    Brkt bracket unit 7-3 62y5a11.

  • Page 173

    62y5a11 7-4 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 tiller handle 1 2 tiller handle wiring harness 1 3 clip 1 4 shift rod 1 5 nut 2 6 bushing 1 7 bolt 1 m12 × 70 mm 8 clip 1 9 throttle cable 1 10 nut 1 11 plastic washer 2 12 metal washer 2 13 wave washer 1 14 pin 1 15 gear 1 16 throttle shaft...

  • Page 174

    Brkt bracket unit 7-5 62y5a11.

  • Page 175

    62y5a11 7-6 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 bracket 1 2 bolt 2 m6 × 16 mm 3 bolt 2 m6 × 16 mm 4 shift arm guide 1 5 nut 1 6 washer 1 7 washer 1 8 bushing 1 9 tiller handle bracket 1 10 nut 1 11 bushing 1 12 engine stop switch 1 13 bolt 1 m6 × 20 mm 14 engine start switch housing 1 15 ...

  • Page 176

    Brkt bracket unit 7-7 62y5a11 bottom cowling 7.

  • Page 177

    62y5a11 7-8 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 shift rod assembly 1 2 bottom cowling 1 3 bolt 1 4 spring 1 5 ball 1 6 shift rod bracket 1 7 cotter pin 1 not reusable 8 washer 1 9 bushing 1 10 bushing 1 11 shift rod 1 12 grommet 1 13 rubber seal 4 14 bolt 4 m6 × 30 mm 15 grommet 4 16 scre...

  • Page 178

    Brkt bracket unit 7-9 62y5a11 checking the throttle cable and shift rod 1. Check the operation of the throttle cable and shift rod. 2. Check the inner wire, outer wire of the cable and rod for bends or damage, and the rubber seals for damage. Replace if necessary. Assembling the tiller handle 1. Ins...

  • Page 179

    62y5a11 7-10 1 2 3 4 5 6 7 8 9 lubricating the throttle gear 1. Inject grease into the grease nipple until grease comes out from the screw hole a. Checking the shift rod assembly operation 1. Check the shift rod assembly and detent for smooth operation. Bottom cowling.

  • Page 180

    Brkt bracket unit 7-11 62y5a11 upper case 7.

  • Page 181

    62y5a11 7-12 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 upper case 1 2 nut 2 3 nut 2 4 washer 2 5 bolt 3 m8 × 30 mm 6 upper mount 1 7 plate 1 8 bolt 2 m8 × 175 mm 9 cap 2 10 bolt 2 m12 × 160 mm 11 grommet 2 12 ground lead 1 13 screw 2 14 mount cover 2 15 bolt 4 m8 × 25 mm 16 mount housing 2 17 s...

  • Page 182

    Brkt bracket unit 7-13 62y5a11.

  • Page 183

    62y5a11 7-14 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 oil seal 1 not reusable 2 exhaust guide 1 3 grommet 1 4 grommet 1 5 anode 1 6 cover 1 7 bolt 1 8 cover 1 9 bolt 1 10 gasket 1 not reusable 11 dowel pin 2 12 bolt 10 m6 × 25 mm 13 oil pan 1 14 gasket 1 not reusable 15 exhaust manifold 1 16 b...

  • Page 184

    Brkt bracket unit 7-15 62y5a11 disassembling the oil pan 1. Remove the muffler 1 from the oil pan 2. 2. Remove the exhaust manifold 3 from the oil pan 2. 3. Remove the oil pan 2 from the exhaust guide 4. 4. Remove the oil strainer 5 and the relief valve housing 6. Caution: do not reuse the gaskets, ...

  • Page 185

    62y5a11 7-16 1 2 3 4 5 6 7 8 9 7. Tighten the exhaust manifold bolts 7, then the oil pan bolts 8. 8. Install the muffler 9 into the oil pan. 9. Install the muffler assembly 0 by insert- ing the tip of the water pipe 4 into the joint hole a of the upper case. Upper case.

  • Page 186

    Brkt bracket unit 7-17 62y5a11 installing the upper case 1. Install the upper mount 1 and bolts 2 into the upper case, and then tighten the bolts 3. 2. Set the lower mounts 4 and bolts to the upper case. 3. Install the end of the spring 5 into the groove of the mount housing 6, and then tighten the ...

  • Page 187

    62y5a11 7-18 1 2 3 4 5 6 7 8 9 clamp brackets 7 no. Part name q’ty remarks 1 swivel bracket assembly 1 2 screw 1 m6 × 15 mm et model 3 trim sensor 1 et model 4 trim sensor coupler 1 et model 5 plastic tie 1 not reusable 6 self-locking nut 2 7 cap 2 8 bolt 1 m6 × 25 mm 9 anode 1 10 port clamp bracket...

  • Page 188

    Brkt bracket unit 7-19 62y5a11 removing the clamp brackets 1. Remove the power trim and tilt or hydro tilt. For removing procedures, see “removing the power trim and tilt/hydro tilt” in this chapter. 2. Loosen the self-locking nuts 1, and then remove clamp brackets 2 and 3. 3. Remove the trim sensor...

  • Page 189

    62y5a11 7-20 1 2 3 4 5 6 7 8 9 adjusting the trim sensor 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. Warning after tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could sud- denly lower if the power...

  • Page 190

    Brkt bracket unit 7-21 62y5a11 swivel bracket and steering arm 7.

  • Page 191

    62y5a11 7-22 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 steering arm 1 2 washer 1 3 bushing 1 4 o-ring 2 not reusable 28.9 × 3.8 mm 5 bushing 2 6 swivel bracket 1 7 bushing 1 8 port tilt stop lever 1 9 circlip 1 10 steering yoke 1 11 bushing 1 12 bushing 1 13 tilt stop lever joint 1 14 spring ho...

  • Page 192

    Brkt bracket unit 7-23 62y5a11 removing the steering arm 1. Remove the circlip 1. 2. Remove the steering yoke 2 by striking it with a plastic hammer. 3. Remove the steering arm from the swivel bracket by pulling the arm off the bracket. Installing the steering arm 1. Install the washer 1, bushing 2,...

  • Page 193

    62y5a11 7-24 1 2 3 4 5 6 7 8 9 6. Inject grease into the grease nipple until grease comes out from both the upper and lower bushings c. Swivel bracket and steering arm.

  • Page 194

    Brkt bracket unit 7-25 62y5a11 power trim and tilt unit 7 no. Part name q’ty remarks 1 power trim and tilt 1 et model 2 hydro tilt 1 ehd/ed models 3 plastic tie 3 not reusable 4 ptt motor lead 2 5 washer 2 6 bolt 2 m8 × 16 mm 7 circlip 1 et model 8 shaft 1 et model 9 bushing 2 et model 10 collar 1 e...

  • Page 195

    62y5a11 7-26 1 2 3 4 5 6 7 8 9 removing the power trim and tilt/hydro tilt 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. Warning after tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could sud- denly ...

  • Page 196

    Brkt bracket unit 7-27 62y5a11 tilt cylinder and trim cylinder 7.

  • Page 197

    62y5a11 7-28 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 power trim and tilt motor 1 2 tilt cylinder end screw 1 3 bolt 3 m5 × 20 mm 4 o-ring 1 not reusable 5 joint 1 6 o-ring 1 not reusable 7 ball 6 8 o-ring 1 not reusable 28.7 × 3.5 mm 9 free piston 1 10 valve seal 1 11 circlip 1 12 circlip 1 1...

  • Page 198

    Brkt bracket unit 7-29 62y5a11 trim cylinder 7.

  • Page 199

    62y5a11 7-30 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 tilt ram 1 2 dust seal 1 not reusable 3 backup ring 1 4 o-ring 1 not reusable 16.8 × 2.4 mm 5 tilt cylinder end screw 1 6 o-ring 1 not reusable 7 backup ring 1 8 o-ring 1 not reusable 16.8 × 2.4 mm 9 trim cylinder end screw 1 10 o-ring 1 no...

  • Page 200

    Brkt bracket unit 7-31 62y5a11 gear pump 7.

  • Page 201

    62y5a11 7-32 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 bolt 2 m5 × 8 mm 2 relief valve bracket 2 3 bolt 3 m6 × 45 mm 4 adapter 1 5 up-relief spring 1 17.5 mm (0.69 in) 6 valve support pin 1 7 relief valve seal 1 8 down-relief spring 1 14.2 mm (0.56 in) 9 valve support pin 1 10 relief valve seal...

  • Page 202

    Brkt bracket unit 7-33 62y5a11.

  • Page 203

    62y5a11 7-34 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 bolt 2 m5 × 20 mm 2 washer 2 3 gear pump bracket 1 4 o-ring 2 not reusable 5.8 × 1.9 mm 5 spring 2 6 spacer 2 7 down-shuttle piston 2 8 up-shuttle piston 1 9 manual release spring 1 10 ball 2 11 gear pump cover 1 12 down-main valve 1 13 o-r...

  • Page 204

    Brkt bracket unit 7-35 62y5a11 disassembling the tilt cylinder 1. Hold the power trim and tilt 1 in a vise using aluminum plates a on both sides. 2. Loosen the tilt cylinder end screw 2, and then remove it. Warning make sure that the ram is fully extended before removing the end screw. 3. Drain the ...

  • Page 205

    62y5a11 7-36 1 2 3 4 5 6 7 8 9 3. Remove the gear pump bracket 6, then the down-shuttle piston 7 and up-shuttle piston 8. 4. Remove the gear pump cover 9, then the down-main valve 0 and up-main valve a. 5. Remove the drive gear b and driven gear c. Checking the tilt cylinder and trim cylinder 1. Che...

  • Page 206

    Brkt bracket unit 7-37 62y5a11 4. Check the down-relief valve 3, up-relief valve 4, and shuttle pistons 5 for dirt or residue. Clean if necessary. Checking the filters 1. Check the gear pump filter 1 and shuttle piston filters 2 for dirt or residue. Clean if necessary. Checking the gear pump 1. Chec...

  • Page 207

    62y5a11 7-38 1 2 3 4 5 6 7 8 9 9. Install the relief valve bracket h by installing the bolts i, then tightening them to the specified torque. 10. Install the filters j and gear pump k by installing the bolts l, then tightening them to the specified torque. 11. Install the manual valve m and reservoi...

  • Page 208

    Brkt bracket unit 7-39 62y5a11 2. Install the o-ring 3 to the end screw. 3. Install the tilt ram 4 into the end screw. 4. Install the backup ring 5 and o-rings 6 and 7 into the trim cylinder end screw 8. 5. Install the trim cylinder end screw onto the tilt ram. 6. Install o-rings 9 and 0 onto the tr...

  • Page 209

    62y5a11 7-40 1 2 3 4 5 6 7 8 9 caution: do not damage the check valve b when tightening the end screw. Assembling the tilt cylinder 1. Install the valve seal 1 and the circlip 2 into the free piston 3 as shown. 2. Install the free piston into the trim cylin- der 4 by installing the circlip 5. 3. Ins...

  • Page 210

    Brkt bracket unit 7-41 62y5a11 7. Install the tilt cylinder end screw c, and then tighten it to the specified torque. 8. Fully extend the tilt rod, and then add suf- ficient fluid of the recommended type to the correct level. 9. Install the reservoir cap d. Bleeding the power trim and tilt (not inst...

  • Page 211

    62y5a11 7-42 1 2 3 4 5 6 7 8 9 7. Reverse the ptt motor leads between the battery terminals when the tilt ram is fully extended, and then reverse them again when it is fully compressed. Note: • repeat this procedure so that the tilt ram goes up and down four to five times. • the sound of the power t...

  • Page 212

    Brkt bracket unit 7-43 62y5a11 power trim and tilt motor 7 no. Part name q’ty remarks 1 screw 3 m5 × 20 mm 2 yoke 1 3 o-ring 1 not reusable 52.0 × 1.9 mm 4 armature 1 5 bushing 1 6 screw 2 m4 × 12 mm 7 wire lead 1 8 brush 2 1 9 brush 1 1 10 brush holder 1 11 circuit breaker 1 12 brush spring 2 13 pt...

  • Page 213

    62y5a11 7-44 1 2 3 4 5 6 7 8 9 checking the power trim and tilt motor 1. Check the commutator for dirt or foreign substances. Clean with #600 grit sand- paper if necessary. 2. Check the commutator undercut for dirt or foreign substances. Clean with com- pressed air if necessary. 3. Measure the commu...

  • Page 214

    Brkt bracket unit 7-45 62y5a11 7. Check the base for cracks or damage. Replace if necessary. 8. Check the bushing 1 for damage or wear. Replace if necessary. Assembling the power trim and tilt motor 1. Install the oil seal 1 and the bushing 2 into the motor base 3 as shown. 2. Attach the circuit bre...

  • Page 215

    62y5a11 7-46 1 2 3 4 5 6 7 8 9 2. Install the shaft 2 and bolts 3 onto both clamp brackets together with the power trim and tilt/hydro tilt 4. 3. Install the tilt ram upper end into the swivel bracket with the shaft 5 and cir- clip(s) 6. 4. Install the tilt pin 7. Power trim and tilt motor.

  • Page 216

    Brkt bracket unit 7-47 62y5a11 power trim and tilt electrical system 7 1 power trim and tilt motor 2 power trim and tilt relay 3 trailer switch 4 fuse 5 battery 6 trim sensor b : black g : green gy : gray l : blue lg : light green p : pink r : red sb : sky blue.

  • Page 217

    62y5a11 7-48 1 2 3 4 5 6 7 8 9 checking the fuse 1. Check the fuse and fuse holder for conti- nuity. Replace if there is no continuity. Checking the power trim and tilt relay 1. Check the power trim and tilt relay for continuity. Replace if out of specification. 2. Connect the digital circuit tester...

  • Page 218

    Brkt bracket unit 7-49 62y5a11 checking the trailer switch 1. Check the trailer switch for continuity. Replace if out of specification. Checking the trim sensor 1. Measure the trim sensor resistance. Replace if out of specification. Note: turn the lever 1 and measure the resistance as it gradually c...

  • Page 219: Electrical Systems

    62y5a11 elec – + 1 2 3 4 5 6 7 8 9 electrical systems special service tools ..................................................................................... 8-1 checking the electrical components............................................................ 8-2 measuring the peak voltage ...........

  • Page 220

    Elec electrical systems – + 8-1 62y5a11 special service tools 8 ignition tester 90890-06754 digital circuit tester 90890-03174 peak voltage adaptor 90890-03172 test harness (2 pins) 90890-06767 vacuum/pressure pump gauge set 90890-06756 dial gauge set 90890-01252 magnet base 90890-06705 test harness...

  • Page 221

    62y5a11 8-2 1 2 3 4 5 6 7 8 9 checking the electrical components 8 measuring the peak voltage the condition of the ignition system can be determined by measuring the peak voltage. Cranking speed is effected by many factors, such as fouled or weak spark plugs, or a weak battery. If one of these facto...

  • Page 222

    Elec electrical systems – + 8-3 62y5a11 electrical components 8 starboard and port views 1 stator 2 pulser coil 3 cdi unit 4 ignition coil 5 oil pressure switch 6 thermoswitch 7 prime start 8 rectifier regulator 9 starter relay 0 starter motor.

  • Page 223

    62y5a11 8-4 1 2 3 4 5 6 7 8 9 front view 1 stator 2 pulser coil 3 cdi unit 4 fuse 5 neutral switch (tiller handle model) 6 starter relay 7 starter motor 8 power trim and tilt relay (power trim and tilt model) È tiller handle model electrical components.

  • Page 224

    Elec electrical systems – + 8-5 62y5a11 top view 1 stator 2 pulser coil 3 cdi unit 4 ignition coil 5 starter motor 6 trailer switch.

  • Page 225

    62y5a11 8-6 1 2 3 4 5 6 7 8 9 tiller handle model 1 engine start switch 2 engine start switch harness 3 engine shut-off switch 4 engine shut-off switch connector 5 neutral switch 6 battery lead electrical components.

  • Page 226

    Elec electrical systems – + 8-7 62y5a11 wiring harness 8 connect to: 1 tiller handle main switch or remote control box or wiring harness extension 2 power trim and tilt relay 3 ground 4 starter relay 5 positive battery lead 6 prime start 7 warning indicator or digital tachometer 8 cdi unit 9 trailer...

  • Page 227

    62y5a11 8-8 1 2 3 4 5 6 7 8 9 ignition system and ignition control system 8 1 spark plug 2 ignition coil 3 charge coil 4 pulser coil 5 engine start switch 6 engine shut-off switch 7 10-pin coupler 8 cdi unit b : black br : brown l : blue w : white b/o : black/orange b/w : black/white w/b : white/bla...

  • Page 228

    Elec electrical systems – + 8-9 62y5a11 8 1 thermoswitch 2 oil pressure switch 3 cdi unit 4 digital tachometer 5 oil pressure warning indicator 6 overheat warning indicator 7 remote control box 8 warning indicator È remote control model É tiller handle model b : black g : green r : red y : yellow gy...

  • Page 229

    62y5a11 8-10 1 2 3 4 5 6 7 8 9 checking the ignition spark gap 1. Disconnect the spark plug caps from the spark plugs. 2. Connect a spark plug cap to the special service tool. 3. Set the spark gap length on the adjusting knob. 4. Crank the engine and observe the spark through the discharge window of...

  • Page 230

    Elec electrical systems – + 8-11 62y5a11 checking the ignition coil 1. Remove the spark plug caps from the high-tension cords by turning the caps counterclockwise. 2. Measure the ignition coil resistance. Replace if out of specification. Checking the cdi unit 1. Measure the cdi unit output peak volt...

  • Page 231

    62y5a11 8-12 1 2 3 4 5 6 7 8 9 warning when checking the peak voltage do not touch any of the connections of the digital tester leads. Note: • use the peak voltage adaptor with the digi- tal circuit tester. • when measuring the peak voltage, set the selector on the digital circuit tester to the dc v...

  • Page 232

    Elec electrical systems – + 8-13 62y5a11 checking the pulser coil air gap 1. Turn the flywheel clockwise to align the projection of the flywheel with the pulser coil projection. 2. Measure the gap between both projec- tions with a thickness gauge. Adjust if out of specification. 3. Remove the flywhe...

  • Page 233

    62y5a11 8-14 1 2 3 4 5 6 7 8 9 checking the thermoswitch 1. Place the thermoswitch in a container of water and slowly heat the water. 2. Check the switch for continuity at the specified temperatures. Replace if out of specification. A temperature b time c no continuity d continuity checking the oil ...

  • Page 234

    Elec electrical systems – + 8-15 62y5a11 starting system 8 1 fuse 2 10-pin coupler 3 engine start switch 4 starter motor 5 battery 6 neutral switch 7 starter relay È tiller handle model b : black br : brown r : red.

  • Page 235

    62y5a11 8-16 1 2 3 4 5 6 7 8 9 checking the fuse 1. Check the fuse and fuse holder for conti- nuity. Replace if there is no continuity. Checking the wiring harness (10 pins) 1. Check the wiring harness for continuity. Replace if there is no continuity. Checking the neutral switch 1. Check the neutra...

  • Page 236

    Elec electrical systems – + 8-17 62y5a11 starter motor 8.

  • Page 237

    62y5a11 8-18 1 2 3 4 5 6 7 8 9 no. Part name q’ty remarks 1 clip 1 2 pinion stopper 1 3 spring 1 4 starter motor pinion 1 5 upper bracket 1 6 o-ring 1 not reusable 7 washer 1 1 8 shim — as required 9 washer 2 1 10 armature 1 11 stator 1 12 o-ring 1 not reusable 13 brush holder assembly 1 14 brush se...

  • Page 238

    Elec electrical systems – + 8-19 62y5a11 removing the starter motor pinion 1. Slide the pinion stopper 1 down as shown, and then remove the clip 2. Checking the starter motor pinion 1. Check the pinion teeth for cracks or wear. Replace if necessary. 2. Check for smooth operation. Replace if necessar...

  • Page 239

    62y5a11 8-20 1 2 3 4 5 6 7 8 9 4. Measure the commutator undercut a. Replace the armature if out of specifica- tion. 5. Check the armature for continuity. Replace if out of specifications. Checking the brushes 1. Measure the brush length. Replace the brush assembly if out of specification. 2. Check ...

  • Page 240

    Elec electrical systems – + 8-21 62y5a11 charging system 8 1 lighting coil 2 rectifier regulator 3 fuse 4 battery b : black g : green r : red g/w : green/white.

  • Page 241

    62y5a11 8-22 1 2 3 4 5 6 7 8 9 checking the lighting coil 1. Measure the lighting coil output peak voltage. Replace the stator coil if below specification. Warning when checking the peak voltage do not touch any of the connections of the digital tester leads. Note: • use the peak voltage adaptor wit...

  • Page 242

    Elec electrical systems – + 8-23 62y5a11 checking the rectifier regulator 1. Measure the rectifier regulator output peak voltage. If below specification, mea- sure the lighting coil output peak voltage. Replace the rectifier regulator if the out- put peak voltage of the lighting coil is above specif...

  • Page 243: Troubleshooting

    62y5a11 trbl shtg 1 2 3 4 5 6 7 8 9 troubleshooting power unit....................................................................................................... 9-1 bracket unit .................................................................................................. 9-10 electrical sy...

  • Page 244

    Trbl shtg troubleshooting 9-1 62y5a11 note: • to diagnose a mechanical malfunction, use the troubleshooting charts pertaining to the trouble located in this chapter. Also, when checking and maintaining the outboard motor, see chapter 4– 8, to check the part necessary to carry out safety maintenance....

  • Page 245

    62y5a11 9-2 1 2 3 4 5 6 7 8 9 check the wiring harnesses for continuity. Replace the wiring harnesses. Check that the combustion camber is filled with engine oil or gasoline. Check the starter motor. Check operation of the starter motor pinion. Remove all spark plugs, and then the engine. Listen for...

  • Page 246

    Trbl shtg troubleshooting 9-3 62y5a11 symptom: engine cranks, but will not start. • check the ignition system. • check the fuel system. • check the compression pressure of power unit. Wet spark plugs? Does the engine start? Wet spark plugs? Out of specifi- cation? Out of specifi- cation? Check the c...

  • Page 247

    62y5a11 9-4 1 2 3 4 5 6 7 8 9 symptom: engine can be started, but does not remain on. • check the fuel system. • check the ignition system. • check the compression pressure of power unit. (fuel system) is the vent screw open? Water or resi- due? Good operat- ing condition? Kinks or fuel leakage? Rep...

  • Page 248

    Trbl shtg troubleshooting 9-5 62y5a11 (ignition system) (compression pressure) check the ignition spark gap using the spark gap tester. Out of specifi- cation? Replace the spark plug. Check the ignition system out- put peak voltage. Yes no is there air intake? Replace the respective seals. Check the...

  • Page 249

    62y5a11 9-6 1 2 3 4 5 6 7 8 9 symptom: the engine idle speed is not steady, but increases or decreases. • check the carburetors. • check the air intake system. • check the ignition system. Replace the cdi unit. Check and disassemble the car- buretors, and then clean them if necessary. Check the thro...

  • Page 250

    Trbl shtg troubleshooting 9-7 62y5a11 symptom: engine does not accelerate when the throttle is opened quickly. The engine turns off when the throttle is opened quickly. Acceleration is tardy and the engine is likely to stop at any moment. • check the carburetors. • check the ignition system. • check...

  • Page 251

    62y5a11 9-8 1 2 3 4 5 6 7 8 9 symptom: engine can run, but engine speed will not increase. Overheat warning indicator is on. Oil pressure warning indicator is on. Warning indicator is on and buzzer is sounding. • check the water cooling system. • check the lubricating system. (cooling system) check ...

  • Page 252

    Trbl shtg troubleshooting 9-9 62y5a11 (lubricating system) check the oil pump for debris or wear. Check the engine oil level. Check the oil pressure. Check the oil pressure switch. Clean or replace the respective parts. At specified level? Out of specifi- cation? Good condi- tion? Debris or wear? Ch...

  • Page 253

    62y5a11 9-10 1 2 3 4 5 6 7 8 9 bracket unit 9 symptom: power trim and tilt unit does not operate. Listen for the operation sound of the power trim and tilt relay. Listen for the operation sound of the power trim and tilt motor. Check that the manual valve is closed. Check the power trim and tilt flu...

  • Page 254

    Trbl shtg troubleshooting 9-11 62y5a11 symptom: power trim and tilt unit does not hold the outboard motor up. Check that the manual valve is closed. Check the power trim and tilt fluid level. Disassemble the power trim and tilt unit, and then check it. Close the valve. Add fluid to the correct level...

  • Page 255

    62y5a11 9-12 1 2 3 4 5 6 7 8 9 symptom: shift mechanism of the forward gear and reverse gear does not operate properly. Check the operation of the shift rod. Check the condition of the shift rod connection between the lower case and upper case. Disassemble the lower case, and then check the shifting...

  • Page 256

    Trbl shtg troubleshooting 9-13 62y5a11 electrical systems 9 symptom: battery becomes weaker quickly. • check the charging system. Measure the rectifier regulator output peak voltage. Replace the lighting coil. Out of specifi- cation? Out of specifi- cation? Replace the rectifier regulator. No no yes...

  • Page 257

    62y5a11 i-1 1 2 3 4 5 6 7 8 9 a. Acceleration pump ....................................1-13 adjusting the dash-pot (acceleration pump) ................................4-15 adjusting the pilot screw ...........................4-13 adjusting the throttle link rod.....................4-13 adjusting the...

  • Page 258

    Index i-2 62y5a11 checking the piston pin boss bore............5-40 checking the piston ring grooves..............5-40 checking the piston ring side clearance ...5-40 checking the piston rings..........................5-39 checking the power trim and tilt fluid level ...................................

  • Page 259

    62y5a11 i-3 1 2 3 4 5 6 7 8 9 installing the lower unit .............................6-22 installing the pinion ...................................6-22 installing the power trim and tilt ................7-45 installing the power unit ............................5-49 installing the propeller shaft ho...

  • Page 260

    Index i-4 62y5a11 w. Water pump and shift rod............................6-7 wiring harness ............................................8-7.

  • Page 262

    Wiring diagram ft50cehd, ft50ced 1 battery 2 engine start switch 3 engine shut-off switch 4 starter motor 5 starter relay 6 neutral switch 7 fuse (20a) 8 prime start 9 warning indicator 0 cdi unit a thermoswitch b oil pressure switch c charge coil d pulser coil e lighting coil f rectifier regulator ...

  • Page 263

    Wiring diagram ft50cet 1 battery 2 power trim and tilt motor 3 power trim and tilt relay 4 starter motor 5 fuse (20a) 6 trim sensor 7 prime start 8 starter relay 9 cdi unit 0 charge coil a lighting coil b pulser coil c rectifier regulator d thermoswitch e oil pressure switch f trailer switch g ignit...

  • Page 265

    Yamaha motor co., ltd. Printed in the netherlands jun. 2001 – 0.4 × 1 cr (ft50cehd, ft50ced, ft50cet) (e).

  • Page 266

    R br p w off on st b ft50cehd, ft50ced l br g g g w/b w/r w/b w/r w/b g/w g/w g/w w/r g/w g g g g l r b g g g r g/w b l g b r p w/b w/r l br p/b y/r b/o w y/b b/w p/w o b p b/w b/w b/o b/o p w b y/b p/b y/r p/w y/b p/b y/r p/w p/b y/b y/b p/b p/w y/r y/r p/w b br l b b w b b p/w y/r b/o b/w y/b p/b ...

  • Page 267

    Ft50cet l b l br g g g w/b w/r w/b w/r w/b g/w g/w g/w w/r g/w g g g g l r b g g g r g/w b l g b r w/b w/r l br p/b y/r b/o w y/b b/w p/w o p p b b/w b/o b/w b/o p w b y/b p/b y/r p/w y/b p/b y/r p/w y/b p/b y/r p/w b br l b b w b b p/w y/r b/o b/w y/b p/b b/o p/w y/r b/w p/b w y/b l l b b b l b b b...